BR112013020426B1 - process and system for manufacturing composite material products - Google Patents

Abstract

PROCESS AND SYSTEM FOR MANUFACTURING PRODUCTS OF COMPOSITE MATERIAL, AS WELL AS PRODUCTS MANUFACTURED WITH THIS PROCESS OR SYSTEM. Process for manufacturing composite material products (44, 48, 52), the process of which comprises at least the following operating steps: - molding at least one main component (18) made of a composite material and one or more secondary components ( 19, 20, 21, 22) made of a composite material by means of one or more main molds (11,13) and one or more secondary molds (23, 24, 25, 26), respectively; disposing one or more intermediate substrates (41) of fibers, in particular carbon fibers, pre-impregnated with a resin, between said secondary components (19, 20, 21, 22) in a molding assembly comprising at least one main mold (11:31) and / or one or more secondary molds (23, 24, 25, 26; 35, 36, 37, 38, 39); resin curing of said intermediate substrates (41) in the molding assembly (40), so that the main component (18) and the secondary components (19,20,21,22) are connected to each other through intermediate substrates ( 41). The present invention also relates to a system that can be used in such a process, as well as products manufactured with this process and / or system.

Description

PROCESS AND SYSTEM FOR MANUFACTURING COMPOSITE MATERIAL PRODUCTS

[001] The present invention relates to a process for the manufacture of composite material products, in particular coatings and ceilings for motor vehicle monocoques. The present invention also relates to a system that can be used in such a process, as well as products manufactured with this process and / or system.

[002] Known monocoques made of a composite material, in particular carbon fiber, are generally manufactured by fixing each other by means of adhesives and / or mechanical members, for example, screws, components of composite material that are molded separately . Such known monocoques are characterized by a high cost, since the entire structure is not intended for exploring the potential of the composite material, and by an average level of repeatability, substantially due to the high use of manual operations within the process of manufacturing. As a matter of fact, monocoques are manufactured from numerous components, all molded separately by means of manual stratification, which are then assembled manually or by means of sticky molds. The components are therefore first produced and subsequently assembled, following the classic production and assembly process typical of the motor vehicle industry. The components are generally obtained through molding processes with carbon fiber substrates pre-impregnated with resin, known as pre-preg, made in layers manually and cured in an autoclave. This process requires long manual labor and expensive materials, moreover it does not guarantee a repeatability comparable to all other parts of the vehicle. Monocoques produced so far are therefore also not very suitable for mass production. The manufacturing processes still require very articulated systems that lead, in most cases, to having dozens of molds reserved for the production of a single component. In addition, the products have to be handled disadvantageously within a few days since the material degrades highly if left at room temperature before the curing cycle, so that such a known process can hardly cope with sudden production stops and involves a high risk of production waste.

[003] The known monocoques are therefore very expensive and difficult to mass produce due to the high number of components with little repetition. The parts are mainly made up of pre-impregnated fibers, which are expensive and require a high skill. Its manufacturing process is also characterized by a clear separation between production and assembly, the molds used have a limited life and the production cycle in which they are used provides the use of a batch of mold in view of a single one by the manufactured one.

[004] Document US489355 describes a bicycle structure manufactured by means of a process in which layers of prepreg are compressed and cured within three main molds in a single molding step. This known molding process is substantially equivalent to said known process for producing monocoocks, since it needs a relatively high number of main molds that can be used only to mold a final product by curing prepreg layers.

[005] WO2008 / 020158 describes a wing box manufactured by means of a process in which layers of prepregs are compressed and cured within main molds comprising removable mandrels that include stringers made from prepregs that have already been cured in those chucks in a preliminary molding step. In this case too, the main molds are used only in a single molding step in which layers of prepregs are cured to form structural parts, in particular a wing surface supported by the stringers, as in the process known above for producing monocoke.

[006] Document EP1216816 refers to a panel reinforced with composite material that has a layer obtained by molding a composite material of fiber-reinforced resin in a flat layer, reinforcements arranged in rows on one layer surface and a fiber material reinforced resin composite sewn into the layer covering the reinforcements. The panel reinforced with composite material being manufactured by a first fabric material that is placed on a tool that has a panel-shaped surface, the reinforcements are then placed on the first fabric material. A second fabric material is placed on the reinforcements to cover at least some of the reinforcements, and is further reformed to match the shape of the reinforcements. The second reformed fabric material is sewn to the first fabric material along the edge of the reinforcements.

[007] EP1764307 relates to a process to manufacture a monolithic leading edge for aerodynamic surfaces of aircraft formed by an outer layer and a plurality of internal ribs, comprising the steps of providing a male tool made to assemble a plurality of blocks, cut layers of dry carbon fibers for the layer and the internal ribs, laminate layers of dry fibers on the sides of said blocks forming half ribs, assemble the male tool with the ribs to be formed with two laminated half ribs on the adjacent blocks integrated in it, laminate layers of dry fibers to the layer on the male tool, place the female tool on the male tool, closing a mold for the next step, and perform a resin injection / curing process under high temperature conditions.

[008] The process and system according to the present invention allows not only to reduce costs, thus allowing the use of composite material products over a mass production volume, but also to ensure the repetition capacity required by the standards of production.

[009] The process includes a curing step, in which at least two components are produced so that a main component acts as a mold for a secondary component. Both components are then cured together by means of intermediate substrates, thus avoiding glue steps. This process can be achieved through a particular modular system that assumes different functions during the production process.

[0010] The intermediate substrates still allow to compensate tolerances, if any, between the components, so that the final product has precise shapes and sizes. For this purpose, the main component is preferably molded between two main molds with an RTM process, so that both, its inner wall and its outer wall have precisely shaped surfaces and sizes.

[0011] The present invention also relates to a monocoque comprising a shell that substantially corresponds to the compartment of a motor vehicle and a roof that covers this shell. These two components are preferably manufactured by means of the process and the system according to the present invention. The process costs are relatively low due to the massive use of production techniques differing from the pre-preg in autoclave, such as the RTM (Resin Transfer Molding) and braiding processes. Both of these processes are based on the formation of a dry fiber layer within molds and subsequent resin injection. The braiding process is based on the automatic weaving of the fibers over a mandrel and the subsequent injection of resin, while the RTM process is based on the deposition of dry fabrics and the subsequent injection of resin. The conformation of the substrates and their subsequent deposition in the molds can be automated, thus making the parts produced with these processes more repeatable and economical.

[0012] The modularity of the molds involves a reduction not only in the number of molds, but also in the number of molds per number of parts: some monocoques produced so far, for example, are produced in a single molding step. The complexity of the geometries and the number of subsets require several dozen molds to manufacture a single component. In the process and system according to the invention, however, the opposite situation exists, in which few molds produce a high number of parts, exactly due to the system's modularity.

[0013] Still an advantage of the process and system is the combination of modular molds, where the parts produced become a mold for the subsequent ones, and the massive use of less aggressive processes than the pre-preg, which leads to a life of the molds expected in 400 pieces for the main molds and 800 pieces for the secondary molds, in view of a life of about 150 pieces of the traditional molds used until now.

[0014] Reducing equipment costs, thus, involves not only a reduction in the number of molds, but also decreasing maintenance and regeneration connected to the molds during their use.

[0015] Another advantage of the process and the system is the possibility of carrying out several stages of production in parallel. Monocoques produced so far in a few very complex molding steps are highly exposed to the risk of rejection. A single complex item is certainly more prone to errors and defects than one manufactured from a greater number of simple and especially unrelated steps. Several steps carried out in parallel allow handling both, possible reconstructions of some components and possible interruptions in production.

[0016] Particular spacers allow both to increase the moment of inertia of the resistant sections of the monocoque, thus giving a high structural rigidity to the latter, and obtain space to accommodate metal inserts for the structural connection with other parts of a motor vehicle. These spacers are preferably arranged between substrates belonging to different sections of the monocoque, but they can be arranged in the middle of the stratification of some components.

[0017] The process is advantageously simplified by molding inserts at given positions in the spacers, so that these inserts are not molded between two substrates of the composite material components, thus reducing the complexity of the work of the substrates. In addition, the inserts are worked, for example, with threaded holes, at the end of the production process, in order to simplify this process and also obtain a final product worked with precision, since the position of the threaded holes does not depend on the position insertions, but is determined by taking the position of the final product as an absolute reference. Thus, with this arrangement, possible inaccurate arrangements for insertions in the final product are compensated.

[0018] The main component, for example, the inner wall of the monocoque shell, is preferably produced with an RTM process, in particular the RTM process according to the Italian patent application MI2010A001072, by means of some main molds, and housings, in the through its stratification, seven spacers preferably provided with metal inserts which are housed within auxiliary molds filled with epoxy foam which is cured to assume the final shape of the spacer. These inserts can also include elements made of a composite material, in particular carbon fiber.

[0019] Particular spacers to be arranged between the main component and the secondary components, for example, between the inner and outer walls of the monocoque shell, can be produced in parallel always with the same process, for example, through the creation of structures of hollow composite material that contains the inserts and that are left empty or filled with epoxy foam.

[0020] Still advantages and characteristics of the process, the system and the products according to the present invention will become apparent to those skilled in the art from the following detailed and non-limiting description of its realization with reference to the accompanying drawings in which:

[0021] Figure 1 shows an enlarged section of the auxiliary molds in a first stage of the process;

[0022] Figure 2 shows an enlarged section of the auxiliary molds of figure 1 in a second stage of the process;

[0023] Figure 3 shows a spacer obtained by means of the auxiliary molds of figure 1;

[0024] Figure 4 shows a perspective view of the main molds in a third stage of the process;

[0025] Figure 5 shows a perspective view of the main molds of figure 4 in a fourth stage of the process;

[0026] Figure 6 shows an enlarged and partial section of the main molds of figure 5;

[0027] Figure 7 shows the section of figure 6 in a fifth stage of the process;

[0028] Figure 8 shows a perspective view of the main molds of Figure 4 in the fifth stage of the process;

[0029] Figures 9 to 12 show perspective views of the secondary molds in a sixth stage of the process;

[0030] Figures 13 to 16 show perspective views of the secondary molds of figures 9 to 12 in a seventh stage of the process;

[0031] Figure 17 shows a perspective view of the molds and components in an eighth stage of the process;

[0032] Figure 18 shows a perspective view of the molds in a ninth stage of the process;

[0033] Figure 19 shows an enlarged and partial section of the molds of figure 18;

[0034] Figure 20 shows the section of figure 19 in a tenth stage of the process;

[0035] Figure 21 shows a perspective view of a shell manufactured using the process;

[0036] Figure 22 shows a top view of the shell of figure 21;

[0037] Figure 23 shows section XXMI-XXMI of figure 22;

[0038] Figure 24 shows detail XXIV of figure 23;

[0039] Figure 25 shows section XXV-XXV of figure 22;

[0040] Figure 26 shows details XXVI of figure 25;

[0041] Figure 27 shows a perspective view of a ceiling manufactured using the process; and

[0042] Figure 28 shows a monocoque comprising the shell of figure 21 and the roof of figure 27.

[0043] Referring to figure 1, it is seen that in a first stage of the process one or more first inserts 1, 2 are arranged in one or more auxiliary molds 3, 4, in particular in contact with at least one functional surface of these molds. The first inserts 1, 2 are preferably made of metal, particularly aluminum or light alloy, of a composite material, in particular carbon fiber, or a combination of these materials, for example, by molding in a preliminary step of an insertion of metal between two or more fiber substrates. Auxiliary molds 3, 4 are preferably made of a composite material, in particular carbon fiber. Auxiliary molds 3 and / or 4 are preferably provided with protrusions 5 and / or seats 6 to hold the first inserts 1, 2 in a given position. For this purpose, the first inserts 1, 2 have complementary shapes with said protuberances 5 and / or seats 6. In particular, protuberances 5 are pins adapted to be inserted in the corresponding holes formed in a first insertion 1, preferably with a coupling with friction, so that insert 1 remains in position even if auxiliary molds 3, 4 are reversed. Also, insert 2 can be arranged in seat 6 with a fraction coupling.

[0044] Referring to figure 2, it is seen that in a second stage of the process, plastic material 7 is injected through entrances and exits 8 in auxiliary molds 3, 4, after which it is cured by heating auxiliary molds 3, 4 in an oven at a temperature between 80oC and 150oC. Auxiliary molds 3, 4 are preferably rotated during heating for uniform distribution of plastic material 7 therein. The plastic material 7 is preferably a material, in particular epoxy foam, which expands during curing.

[0045] Referring to figure 3, it is seen that, after the epoxy foam has cured, the auxiliary molds 3, 4 are cooled to a temperature below 50oC, opened and separated from the product 7, which in particular forms a first spacer for composite material products. Spacer 7 thus comprises the cured epoxy foam which incorporates at least partially the first inserts 1, 2, which can protrude from the first spacer 7 or have a visible surface outside the first spacer 7. Insert holes 9 for pins 5 are then open to the outside.

[0046] Referring to figures 4 to 6, it is seen that in a third stage of the process one or more, in particular the first two main substrates 10 of fibers, in particular carbon fibers, preferably dry, for example, coupled with an amount of resin from 0 to 10%, preferably 5% by weight, is arranged on at least one functional surface of a first main mold 11. One or more first spacers, in particular one or more first spacers 7 with a or more first inserts 1, 2 manufactured as described above, can be arranged in contact with the first main substrates 10 and / or with the first main mold 11. One or more, in particular two second main fiber substrates 12, in particular fibers of carbon, preferably dried, are then arranged on the first main substrate 10 and / or on the first main mold 11 and / or on first spacers 7. At least a portion of the first spacers 7 is preferably arranged between the first main substrates 10 and the second substrates 12. At least one second main mold 13 is aligned with the first main mold 11, for example, by means of pins and complementary holes, and is fixed to the first main mold 11, for example, by means of mechanical clamping devices, in particular lever latches and / or screws, so that the first main substrates 10, the first spacers 7 and the second main substrates 12 are arranged between the functional surfaces of the main molds 11 , 13. The main molds, in particular the second main mold 13, can be provided with movable walls 14 and / or blocks 15 for forming recessed portions and / or deep cavities, respectively, in a molded product. In figure 4 the main substrates 10, 12 are shown for simplicity with a rectangular shape, however, each main substrate 10, 12 can be divided into a plurality of portions having different shapes, sizes, thicknesses and / or wefts, whose portions are preferably cut by numerical control machines. Also, the first spacers 7 can have shapes and / or dimensions differing from those shown in figure 4.

[0047] In a fourth stage of the process operation, resin 16 for composite materials is injected at a pressure between 50 KPa and 350 KPa (0.5 and 3.5 bar), in particular between 150 KPa and 250 KPa (1, 5 and 2.5 bar), through one or more inlets 17 between the main molds 11, 13, preferably evacuated to a pressure less than 50 KPa (0.5 bar), in particular comprised between 0.1 and 2 KPa ( 0.001 and 0.02 bar), through one or more outlets, in order to impregnate the main substrates 10, 12 with resin 16. Resin 16 is then cured by heating main molds 11, 13 in an oven for molding hair least one major component. The main molds 11 and / or 13 are preferably heated, in particular to a temperature comprised between 25oC and 70oC, before injection of resin 16 into them. The main molds 11 and / or 13 are preferably made of a composite material, in particular they are made of a plurality of fiber substrates, in particular carbon fibers, pre-impregnated with a resin that is cured in a preliminary step to obtain the finished molds 11 and / or 13. The first main mold 11 has a mainly convex functional surface, while the second main mold 13 has a mainly concave functional surface. In particular, the first main mold 11 has a functional surface with two convex portions separated by a concave channel, while the second main mold 13 has a functional surface with two concave portions separated by a convex channel. The cross sections of the convex portions and / or the concave channel of the first main mold 11 and / or the concave portions and / or the convex channel of the second main mold 13 are substantially rectangular or substantially trapezoidal.

[0048] Referring to figures 7 and 8, it is seen that in a fifth stage of the process the main molds 11, 13 are cooled, opened at a temperature between 40oC and 70oC, then separated from the main component 18 comprising the main substrates that they are cured with resin 16 to form at least one inner wall 10 and / or an outer wall 12, respectively, of the main component 18 with at least one first spacer 7 disposed between these walls 10, 12. In an alternative process step, the main component 18 remains on the first main mold 11, so that the inner wall 10 remains in contact with the functional surface of the first main mold 11.

[0049] Referring to figures 9 to 12, it is seen that in a sixth stage of the process, which can be performed before, during or after the previous stages, one or more, in particular two secondary substrates 19, 20, 21, 22 fibers, in particular carbon fibers, preferably pre-impregnated (pre-preg), for example, coupled with an amount of resin greater than 10% by weight, are arranged on at least one functional surface of at least one first mold secondary 23, at least one secondary mold 24, at least a third secondary mold 25 and at least a fourth secondary mold 26, respectively. One or more second inserts 27, 28, 29, 30, preferably of metal, in particular plates made of aluminum or light alloy, and / or of a composite material, can be arranged between two secondary substrates or between a secondary substrate and a mold secondary or outside the secondary substrates, which are then arranged between a secondary insert and a secondary mold. In figures 9 and 12 the second inserts 27, 30 are arranged between the two secondary substrates 19 or 22, respectively, while in figures 10 and 11 the secondary inserts 28, 29 are arranged between the secondary substrates 20, 21 and the second secondary mold. 24 or the third secondary mold 25, respectively. In figures 9 to 12 the secondary substrates 19, 20, 21, 22 are shown for simplicity with a rectangular shape, however, each secondary substrate 19,20, 21, 22 can be divided into a plurality of portions having different shapes, sizes, thickness and / or wefts. Also, the second inserts 27, 28, 29, 30 may have shapes and / or dimensions differing from those shown in figures 9 to 12.

[0050] Secondary molds 23, 24, 25, 26 with secondary substrates 19, 20, 21, 22 and second inserts 27, 28, 29, 30 are inserted in vacuum bags, heated to a temperature greater than 120oC and arranged in an autoclave at a pressure greater than 500 KPa (5 bar), so that the secondary substrates 19, 20, 21,22 and the secondary inserts 27, 28, 29, 30 are pressed on the secondary molds 23, 24, 25, 26 while the secondary substrate resin 19, 20, 21,22 is cured.

[0051] Referring to figures 13 to 16, it is seen that in a seventh stage of the process the secondary substrates 19, 20, 21, 22, after the resin has cured, form secondary components 19, 20, 21, 22 having at least at least one surface corresponding to at least one functional surface of the secondary molds 23, 24, 25, 26. Secondary components 19, 20, 21, 22 can be separated from or left on the secondary molds 23, 24, 25, 26. Secondary molds 23, 24, 25, 26 have a mainly concave functional surface.

[0052] Referring to figure 17, it is seen that in an eighth stage of the process the main component 18 is disposed on at least one first main mold 31 having at least one functional surface substantially equal to a functional surface of the first main mold 11, or alternatively, the main component 18 is left on the first main mold 11. One or more, in particular three second spacers 32, 33, 34, preferably covered by at least one adhesive layer, are arranged on the main component 18 The at least one adhesive layer is preferably applied to the portions of the main component 18 not covered by the second spacers 32, 33, 34, after which one or more, in particular two intermediate substrates (not shown in the figure) of fibers, in carbon fibers, pre-impregnated with a resin (pre-preg), are arranged on the second spacers 32, 33, 34 and / or on the main component 18 arranged on the first main mold 11 or 31.

[0053] During the deposition of the intermediate substrates on the main component 18 and / or the second spacers 32, 33, 34, the intermediate substrates can be covered by at least one anti-adhesive sheet and the secondary components 19, 20, 21, 22 can temporarily placed on the intermediate substrates to verify the correct position of the second spacers 32, 33, 34, preferably by arranging secondary molds 23, 24, 25, 26 on secondary components 19, 20, 21, 22, after which secondary components 19, 20, 21, 22 and the anti-adhesive sheet are removed.

[0054] The intermediate substrates are then pressed onto the main component 18 by means of a vacuum bag, after which the at least one adhesive layer is preferably disposed on the intermediate substrates. Secondary components 19, 20, 21, 22 are then arranged on the intermediate substrates and / or on the second spacers 32, 33, 34 and / or on the main component 18 by means of secondary molds 35, 36, 37, 38 which have at least one functional surface substantially equal to a functional surface of the secondary molds 23, 24, 25, 26, respectively. As an alternative to the secondary molds 35, 36, 37, 38, the secondary components 19, 20, 21,22 are left on the secondary molds 23, 24, 25, 26.

[0055] The main molds 11, 13 and / or 31 and the secondary molds 23, 24, 25, 26 and / or 35, 36, 37, 38 are suitably provided with surfaces with shapes and / or elements, for example, pins and holes, for making a mechanical coupling with corresponding shapes and / or elements, for example, holes and pins, of at least one main mold 11, 13,31, and / or at least one secondary mold 23, 24, 25 , 26, 35, 36, 37, 38 and / or at least one secondary mold 39 having a functional surface substantially equal to at least a portion of a functional surface of the second main mold 13.

[0056] Referring to figure 18, it is seen that in a ninth stage of the process the first main molds 11 and / or 31 and the secondary molds 23, 24, 25, 26, 35, 36, 37, 38 and / or 39 are fixed to each other with mechanical fixing devices, in particular lever latches and / or screws, to form a modular mold assembly 40. The first main molds 11 and / or 31 are preferably mounted on a cart (not shown) in the figure) which is equipped with a closing system that allows a mutual movement between mold and cart, in order to be able to move the molding assembly 40 more easily.

[0057] Referring to figure 19, it is seen that the main component 18 and the secondary component 20 provided with the second insert 28 are disposed between a first main mold, for example, still the first main mold 31, and a secondary mold , for example, still the second secondary mold 36. The second spacer 33 is disposed between the main component 18 and the secondary component 20, while the intermediate substrates 41 are disposed between the second spacer 33 and the secondary component 20. The second spacers 32 , 33 and / or 34 are preferably made of a composite material, in particular preferably dry carbon fiber, and are molded by means of an RTM process or by braiding in a preliminary step to form a hollow body 42 having a cavity 43 which can be left empty or filled with plastic material, in particular epoxy foam. The molding assembly 40 is then heated, in particular in an oven to at least 130oC and / or for at least 3 hours, in order to cure the resin of the intermediate substrates 41, which form after curing a single body with the main component 18, with the secondary components 19, 20, 21, 22 and / or with the second spacers 32, 33, 34. During the curing of the resin of the intermediate substrates 41 in the molding assembly 40, still a main component can be molded by means of of the main molds 11, 13 and / or one or more secondary components can be molded by means of the secondary molds 23, 24, 25, 26.

[0058] Referring to figure 20, it is seen that in a tenth step of the process the molding assembly 40 is opened and the final product 44 comprising the main component 18 connected to the secondary components 19, 20, 21,22 through the intermediate substrates 41, is separated from the main mold 31 and the secondary molds 35, 36, 37, 38, 39. The final product 44 is then placed on a support and mechanically worked, preferably by numerical control tools on five axes, for forming of threaded holes 45 and / or non-threaded holes 46 and / or recesses 47 and / or openings in the final product 44 and in particular in the inserts included in the final product 44, for example, in the first insert 1 and the second insert 28, so to fix elements and / or structures to the final product 44. Metal inserts having at least one outward facing surface, such as the second insert 28, can also be recessed to obtain precise reference surfaces dimensions and positions.

[0059] Referring to figures 21 to 26, it is seen that a shell 48 of a monocoque can comprise said final product 44, for example, it can be manufactured by means of the process and / or the molds according to the present invention. Shell 48 is then provided with at least one internal structure comprising the main component 18, the internal structure of which is connected to an external structure comprising the secondary components 19, 20, 21, 22. The lower side portions of the shell 48, corresponding to the thresholds of the monocoque door, comprise the second spacers 32, 34, which preferably have a substantially tubular shape and / or are hollow and / or are manufactured with the braiding technique. At least one insert 49 can be arranged in the second spacers 32, 34. The lower rear shell portion 48, corresponding to the bench behind seats in the monocoque, comprises the second spacer 33, which is preferably hollow and / or manufactured with an RTM process . The upper front shell portion 48, corresponding to the base of the monocoque windshield, comprises at least one pair of substantially wedge-shaped cavities 50, 51 which are obtained by means of blocks 15 of the second main mold 13.

[0060] Referring to figures 27 and 28, it is seen that a roof 52 of a monocoque can comprise said final product 44, for example, it can be manufactured by means of the process and / or the molds according to the present invention. Ceiling 52 has at least a pair of projections 53, 54 that protrude downwardly beneath the frame for a windshield and are substantially complementary in shape to cavities 50, 51, for example, substantially wedge-shaped, so that in a final assembly step, the ceiling 52 can be fixed on shell 48 using fixing projections 53, 54 in cavities 50, 51, preferably by means of adhesive substances, to form a monocoque 55. Ceiling 52 can be fixed to shell 48 also by means of mechanical fastening elements.

[0061] Any variants and / or additions can be made by those skilled in the art for carrying out the invention described and illustrated herein while remaining within the scope of the claims that follow. In particular, further embodiments of the invention may comprise the technical characteristics of one or more of the following claims with the addition of one or more technical characteristics, taken individually or in any mutual combination, described in the text and / or illustrated in the drawings.

Claims (19)

Process for manufacturing composite material products (44, 48, 52), characterized by the fact that it comprises the following steps of operation:
molding a main component (18) made of a composite material and one or more secondary components (19, 20, 21, 22) made of a composite material by means of one or more main molds (11, 13) and one or more molds secondary (23, 24, 25, 26), respectively, in which the main component (18) is obtained by curing resin (16) which is injected through one or more entries (17) between the main molds (11, 13) to impregnate main substrates (10, 12) arranged between the main molds (11,13);
arranging one or more intermediate substrates (41) of fibers, in particular carbon fibers, pre-impregnated with a resin, between said main component (18) and / or said secondary components (19, 20, 21, 22) in a molding assembly (40) comprising a main mold (11; 31) and / or one or more secondary molds (23, 24, 25, 26; 35, 36, 37, 38, 39), so that the main component (18) is arranged on one side of an intermediate substrate (41) and a secondary component (19, 20, 21, 22) is arranged on the other side of this intermediate substrate (41) between a main mold (11; 31) and a secondary mold (23, 24, 25, 26; 35, 36, 37, 38, 39) of the molding assembly (40);
cure the resin of said intermediate substrates (41) in the molding assembly (40), so that the main component (18) and the secondary components (19, 20, 21, 22) are connected to each other through intermediate substrates ( 41). Process according to claim 1, characterized in that a main mold (11) used to mold the main component (18) is a main mold (11) of the molding assembly (40). Process according to claim 1 or 2, characterized in that a main mold (31) of the molding assembly (40) has a functional surface substantially equal to a functional surface of a main mold (11) used to mold the main component (18). Process according to any one of the preceding claims, characterized by the fact that one or more secondary molds (23, 24, 25, 26) used to mold the secondary components (19, 20, 21,22) are secondary molds (23 , 24, 25, 26) of the molding assembly (40). Process according to any one of the preceding claims, characterized by the fact that one or more secondary molds (35, 36, 37, 38) of the molding assembly (40) have a functional surface substantially equal to a functional surface of one or more plus secondary molds (23, 24, 25, 26) used to mold the secondary components (19, 20, 21,22). Process according to any one of the preceding claims, characterized in that a secondary mold (39) of the molding assembly (40) has a functional surface substantially equal to a portion of a functional surface of a main mold (13) used to mold the main component (18). Process according to any one of the preceding claims, characterized by the fact that the main molds (11, 13; 31) and the secondary molds (23, 24, 25, 26; 35, 36, 37, 38, 39) are provided with surfaces with shapes and / or elements for carrying out a mechanical coupling with corresponding shapes and / or elements of a main mold (11, 13; 31) and / or a secondary mold (23, 24, 25, 26; 35 , 36, 37, 38, 39). Process according to any of the preceding claims, characterized by the fact that said resin (16) is injected at a pressure between 50 KPa and 350 KPa (0.5 bar and 3.5 bar), in particular between 150 and 250 KPa (1.5 and 2.5 bar), between the main molds (11, 13). Process according to any one of the preceding claims, characterized by the fact that one or more secondary components (19, 20, 21, 22) are obtained by molding on a secondary mold (23, 24, 25, 26) of a or more secondary substrates (19, 20, 21,22) of fibers, in particular carbon fibers, pre-impregnated with a resin. Process according to any one of the preceding claims, characterized by the fact that said composite material product (44, 48, 52) is worked mechanically after the resin of the intermediate substrates (41) has been cured. Process according to any one of the preceding claims, characterized by the fact that the intermediate substrates (41) are pressed onto the main component (18) by means of a vacuum bag before curing its resin. Process according to any of the preceding claims, characterized by the fact that an adhesive layer is disposed on the intermediate substrates (41) before curing its resin. Process according to any one of the preceding claims, characterized by the fact that during the curing of the resin of the intermediate substrates (41) in the molding assembly (40), an additional main component is molded by means of the main molds (11, 13 ) and / or one or more additional secondary components are molded by means of the secondary molds (23, 24, 25, 26). System for manufacturing composite material products (44, 48, 52) which uses the process for manufacturing composite material products (44, 48, 52) as defined in claim 1, whose system comprises two main molds (11, 13 ; 31) suitable for molding a main component (18), as well as one or more inlets (17) suitable for injecting resin (16) between the main molds (11, 13), wherein one or more secondary molds (23, 24 , 25, 26; 35, 36, 37, 38, 39) suitable for molding one or more secondary components (19, 20, 21, 22) are provided with shaped surfaces and / or elements for performing a mechanical coupling with corresponding shapes and / or elements of a main mold (11; 31) and / or a secondary mold (23, 24, 25, 26; 35, 36, 37, 38, 39) for forming an appropriate molding assembly (40) to mold a product (44, 48, 52) comprising the main component (18) and the secondary components (19, 20, 21,22), characterizes due to the fact that the system still comprises vacuum bags suitable to contain the secondary molds (23, 24, 25, 26; 35, 36, 37, 38, 39) and an autoclave suitable for containing the secondary molds (23, 24, 25, 26; 35, 36, 37, 38, 39) inserted in these vacuum bags. System according to claim 14, characterized in that a main mold (11) suitable for molding the main component (18) is a main mold (11) of the molding assembly (40). System according to claim 14 or 15, characterized in that a main mold (31) of the molding assembly (40) has a functional surface substantially equal to a functional surface of a main mold (11) suitable for molding the main component (18). System according to any one of claims 14 to 16, characterized in that one or more secondary molds (23, 24, 25, 26) suitable for molding the secondary components (19, 20, 21,22) are secondary molds (23, 24, 25, 26) of the molding assembly (40). System according to any one of claims 14 to 17, characterized in that one or more secondary molds (35, 36, 37, 38) of the molding assembly (40) have a functional surface substantially equal to a functional surface of one or more secondary molds (23, 24, 25, 26) suitable for molding the secondary components (19, 20, 21,22). System according to any one of claims 14 to 18, characterized in that a secondary mold (39) of the molding assembly (40) has a functional surface substantially equal to a portion of a functional surface of a main mold (13 ) suitable for molding the main component (18).

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